System and method for a robotic manipulator system

ABSTRACT

A robotic arm control system including a robotic arm configured to deploy one or more tools in an operating space, one or more sensors, and a control system operably configured to: scan the operating space with the one or more sensors, identify a surface of the operating space based at least in part upon information sensed by the one or more sensors, establish a virtual barrier offset from the surface, and limit movement of the robotic arm based at least in part upon the virtual barrier.

RELATED FILINGS

The following application claims priority to U.S. ProvisionalApplication Ser. No. 62/337,066, filed May 16, 2016 and U.S. patentapplication Ser. No. 15/591,978, filed on May 10, 2017, which areincorporated by reference in their entirety.

COPYRIGHT NOTICE

Contained herein is material that is subject to copyright protection.The copyright owner has no objection to the facsimile reproduction byanyone of the patent document or the patent disclosure, as it appears inthe United States Patent and Trademark Office patent file or records,but otherwise reserves all rights to the copyright whatsoever. Thefollowing notice applies to the software, screenshots and data asdescribed below and in the drawings hereto and All Rights Reserved.

TECHNICAL FIELD OF THE INVENTION

This disclosure relates generally to robotic systems designed to performoperations in hazardous and/or difficult to access spaces.

BACKGROUND

Certain industrial project environments are hazardous to humans, andgenerally require workers to wear protective clothing and a breathingapparatus to enter and work in the area. Also, the space or area forcertain projects is often not designed with human movement in mind,meaning the space can be too small, too hot, too cold, or generallydifficult or impossible for humans to navigate. Some industrial projectareas are so hazardous and difficult to access that human entry andrepairs are altogether unfeasible. To gain access to such areas, and toreduce human exposure to hazardous conditions, remote roboticmanipulators are a necessity.

Currently, most off-the-shelf remote manipulators are built for aspecific need and are limited in capabilities and versatility.Therefore, a need exists for an all-in-one manipulator with increasedcapability, versatility, and reliability for carrying out operations indifficult to access and/or hazardous spaces.

To reduce the complexity and length of the Detailed Specification,Applicant(s) herein expressly incorporate(s) by reference the followingmaterials identified in each paragraph below. The incorporated materialsare not necessarily “prior art” and Applicant(s) expressly reserve(s)the right to swear behind any of the incorporated materials.

System and Method for a Robotic Manipulator Arm, Ser. No. 62/337,066filed May 16, 2016, which is hereby incorporated by reference in itsentirety, and to which the present application claims priority.

Tank Cleaning System, Ser. No. 62/330,330 filed May 2, 2016, which ishereby incorporated by reference in its entirety.

Systems and Methods for Chain Joint Cable Routing, Ser. No. 14/975,544filed Dec. 18, 2015, with a priority date of Dec. 19, 2014, which ishereby incorporated by reference in its entirety.

System and Method for Inspection and Maintenance of Hazardous Spaces,Ser. No. 15/341,985 filed Nov. 2, 2016, with a priority date of Nov. 3,2015, which is hereby incorporated by reference in its entirety.

Rolatube Deployment Mechanism, Ser. No. 62/406,209 filed Oct. 10, 2016,which is hereby incorporated by reference in its entirety.

Applicant(s) believe(s) that the material incorporated above is“non-essential” in accordance with 37 CFR 1.57, because it is referredto for purposes of indicating the background or illustrating the stateof the art. However, if the Examiner believes that any of theabove-incorporated material constitutes “essential material” within themeaning of 37 CFR 1.57(c)(1)-(3), applicant(s) will amend thespecification to expressly recite the essential material that isincorporated by reference as allowed by the applicable rules.

Aspects and applications presented here are described below in thedrawings and detailed description. Unless specifically noted, it isintended that the words and phrases in the specification and the claimsbe given their plain, ordinary, and accustomed meaning to those ofordinary skill in the applicable arts. The inventors are fully awarethat they can be their own lexicographers if desired. The inventorsexpressly elect, as their own lexicographers, to use only the plain andordinary meaning of terms in the specification and claims unless theyclearly state otherwise and then further, expressly set forth the“special” definition of that term and explain how it differs from theplain and ordinary meaning. Absent such clear statements of intent toapply a “special” definition, it is the inventors' intent and desirethat the simple, plain and ordinary meaning to the terms be applied tothe interpretation of the specification and claims.

The inventors are also aware of the normal precepts of English grammar.Thus, if a noun, term, or phrase is intended to be furthercharacterized, specified, or narrowed in some way, then such noun, tern,or phrase will expressly include additional adjectives, descriptiveterms, or other modifiers in accordance with the normal precepts ofEnglish grammar. Absent the use of such adjectives, descriptive terms,or modifiers, it is the intent that such nouns, terms, or phrases begiven their plain, and ordinary English meaning to those skilled in theapplicable arts as set forth above.

Further, the inventors are fully informed of the standards andapplication of the special provisions of 35 U.S.C. § 112, ¶6. Thus, theuse of the words “function,” “means” or “step” in the DetailedDescription or Description of the Drawings or claims is not intended tosomehow indicate a desire to invoke the special provisions of 35 U.S.C.§ 112, ¶6, to define the systems, methods, processes, and/or apparatusesdisclosed herein. To the contrary, if the provisions of 35 § 112, ¶6 aresought to be invoked to define the embodiments, the claims willspecifically and expressly state the exact phrases “means for” or “stepfor, and will also recite the word “function” (i.e., will state “meansfor performing the function of . . . ”), without also reciting in suchphrases any structure, material or act in support of the function. Thus,even when the claims recite a “means for performing the function of . .. ” or “step for performing the function of . . . ”, if the claims alsorecite any structure, material or acts in support of that means or step,or that perform the recited function, then it is the clear intention ofthe inventors not to invoke the provisions of 35 U.S.C. § 112, ¶6.Moreover, even if the provisions of 35 U.S.C. § 112, ¶6 are invoked todefine the claimed embodiments, it is intended that the embodiments notbe limited only to the specific structure, material or acts that aredescribed in the preferred embodiments, but in addition, include any andall structures, materials or acts that perform the claimed function asdescribed in alternative embodiments or forms, or that are well knownpresent or later-developed, equivalent structures, material or acts forperforming the claimed function.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the systems, methods, processes, and/orapparatuses disclosed herein may be derived by referring to the detaileddescription when considered in connection with the followingillustrative figures. In the figures, like-reference numbers refer tolike-elements or acts throughout the figures.

FIG. 1 depicts an isometric view of an embodiment of a deployed RoboticManipulator Arm (RMA).

FIG. 2A depicts an isometric view of an embodiment of an un-deployedRMA.

FIG. 2B is a side view of the internal components of the un-deployed RMAembodiment of FIG. 2A.

FIG. 3A depicts an isometric view of an embodiment of an RMA at thebeginning of a deployment procedure.

FIG. 3B depicts the embodiment of FIG. 3A as the carriage lifts upwardsabout 15° and the forearm enters the access point.

FIG. 3C depicts the embodiment of FIG. 3A as the carriage lifts upwardsabout 45° and the forearm extends farther into the access point.

FIG. 3D depicts the embodiment of FIG. 3A as the carriage is lowered tothe base of the frame.

FIG. 3E depicts the embodiment of FIG. 3A as the reaches the base of theframe and reaches 90°.

FIG. 3F depicts the embodiment of FIG. 3A as the carriage lifts upwardsabout 120°.

FIG. 3G depicts the embodiment of FIG. 3A as the carriage nears 180° inrelation to its original position and the elbow has entered the accesspoint.

FIG. 4A depicts an embodiment of an RMA with the mast retracted.

FIG. 4B depicts the embodiment of FIG. 4A with the mast extended.

FIG. 5 depicts an embodiment of an elbow.

FIG. 6A depicts an isometric view of an embodiment of an RMA elbow isoriented vertically downwards and the mast and forearm are both fullyextended.

FIG. 6B depicts an isometric view of the embodiment of FIG. 6A with a90-degree actuation of the mast-elbow pivot lifting the forearm to ahorizontal position.

FIG. 6C depicts an isometric view of the embodiment of FIG. 6A with a90-degree actuation of the forearm-elbow pivot lifting the forearmtowards a vertical upward position.

FIG. 7A depicts an embodiment of an extendable RMA forearm when it isretracted.

FIG. 7B depicts the embodiment of FIG. 7A when the forearm is extended.

FIG. 8A depicts an isometric view of an embodiment of a wrist joint at0°.

FIG. 8B depicts the wrist joint embodiment of FIG. 8A at −90°.

FIG. 8C depicts the wrist joint embodiment of FIG. 8A at +90°.

FIG. 9A depicts an embodiment of an end effector coupling mechanism forcoupling an end effector to a forearm.

FIG. 9B depicts an embodiment of a wrist coupling mechanism on anembodiment of a forearm corresponding to the end effector couplingmechanism embodiment of FIG. 9A.

FIG. 9C depicts the coupling mechanism embodiments of FIGS. 9A and 9Bwhen coupled and the wrist is bent 90° downward.

FIG. 9D depicts the coupling mechanism embodiments of FIGS. 9A and 9Bwhen coupled and the wrist is bent 90° upward.

FIG. 10A depicts an isometric view of an embodiment of a gripper endeffector.

FIG. 10B depicts a rear view of the embodiment of FIG. 10A.

FIG. 11A depicts an isometric view of the RMA end effector change.

FIG. 11B depicts the insertion of an end effector into the RMA.

FIG. 11C depicts the forearm of the RMA extending to connect to an endeffector embodiment.

FIG. 12 depicts an end effector embodiment coupled to the RMA.

FIG. 13 depicts an isometric view of an end effector embodiment coupledwith a waterjet tool.

FIG. 14 is an example embodiment depicting virtual barriers in anoperating space.

FIG. 15 depicts an embodiment of a control system.

FIG. 16 depicts an embodiment of the forearm comprising sensors.

Elements and acts in the figures are illustrated for simplicity and havenot necessarily been rendered according to any particular sequence orembodiment.

DESCRIPTION

In the following description, and for the purposes of explanation,numerous specific details, process durations, and/or specific formulavalues are set forth in order to provide a thorough understanding of thevarious aspects of exemplary embodiments. It will be understood,however, by those skilled in the relevant arts, that the apparatus,systems, and methods herein may be practiced without these specificdetails, process durations, and/or specific formula values. It is to beunderstood that other embodiments may be utilized and structural andfunctional changes may be made without departing from the scope of theapparatus, systems, and methods herein. In other instances, knownstructures and devices are shown or discussed more generally to avoidobscuring the exemplary embodiments. In many cases, a description of theoperation is sufficient to enable one to implement the various forms,particularly when the operation is to be implemented in software. Itshould be noted that there are many different and alternativeconfigurations, devices, and technologies to which the disclosedembodiments may be applied. The full scope of the embodiments is notlimited to the examples that are described below.

In the following examples of the illustrated embodiments, references aremade to the accompanying drawings which form a part hereof, and in whichis shown by way of illustration various embodiments in which thesystems, methods, processes, and/or apparatuses disclosed herein may bepracticed. It is to be understood that other embodiments may be utilizedand structural and functional changes may be made without departing fromthe scope.

To prevent workers from needing to enter environments that are hazardousor within confined or difficult to reach spaces, a remotely operablerobotic manipulator arm (RMA) is disclosed. The RMA may be used toremotely inspect, maintain, and clean difficult to access and/orhazardous spaces of a variety of different shapes, sizes, and technicalconstraints with little to no direct human interaction required. The RMAis versatile, durable, reusable, decreases operational risk, andincreases operator safety. In some embodiments, the RMA may be one ormore of radiation resistant, temperature tolerant, freeze protected,humidity tolerant, chemical resistant, and seismic/wind/weathertolerant, among others.

The RMA in some embodiments is designed and configured such that it canbe transported and installed in existing locations without affectingpre-existing infrastructure or requiring heavy machinery. In someembodiments, the RMA may be installed and deployed within extremelytight quarters. In some embodiments deployment of the RMA does notrequire expensive or specialized tooling. During deployment andretrieval, the RMA carriage in some embodiments may follow a specificcam path allowing the manipulator to travel vertically up and downthrough an access point. Manual deployment in some embodiments can becarried out quickly and efficiently, limiting worker exposure to thearea of operations. After the RMA has completed operations, it may bewashed down on site, retrieved from the workspace, and may be removedfrom the site in the reverse order in which it was installed. The RMAmay be redeployed at the same or other sites.

The terms “site”, “tank”, “compartment”, “hazardous space”, “workspace”,“area of operations”, “confined space”, and other such references aremerely used to reference a space within which the system may performoperations and are not intended as limitations.

The workspace in some embodiments may variously contain one or more ofion exchange resin, sludge, effluent, toxic waste, and other potentiallyhazardous and/or difficult to remove materials. In some embodiments, thepurpose of the RMA is to facilitate the necessary operations to inspectworkspaces, remove any remaining materials, clean the workspace, andinstall or uninstall devices in the space, among other operations. TheRMA may allow for the attachment of various standard and/or customizedtools that may be maneuvered within workspaces to carry out a variety ofdiffering operations. In an example embodiment, the RMA can remove bulkion exchange material and sand using a suction tool while being fullysubmerged in effluent.

System Overview

FIG. 1 depicts an isometric view of an embodiment of a roboticmanipulator arm (RMA) 100 when partially extended. The RMA 100 in someembodiments is operable to carry out inspection, maintenance, repairs,and cleaning operations in difficult to access and/or hazardousenvironments. The RMA 100 in the depicted embodiment comprises a supportframe 10, carriage 115, mast 120, forearm 130, elbow 140, wrist 150, andan end effector 160. Some embodiments may comprise additionalcomponents, or more than one of one or more of the depicted components.In some embodiments, at least one of the mast and forearm are extendableby means such as telescoping. The degrees of freedom for the depictedembodiment are vertical mast extension/retraction, mast rotation, elbowpivots, forearm extension/retraction, wrist pitch, and wrist roll. Insome embodiments, additional tools and carts may be used depending onthe application and project requirements.

In some embodiments, the RMA 100 is sized and configured to betransportable. In some embodiments, the RMA 100 is designed to be easilymaneuvered through existing rooms and doors, taking into considerationconstraints comprising limited head room, access in and out of doorways,existing equipment and infrastructure, and access points. The RMA 100may be scaled to its intended application. In an embodiment, the RMA 100has a vertical reach of 32 feet and a horizontal reach of 15 feet whenfully extended. Other versions of vertical and horizontal reach arepossible depending on how the RMA is scaled to its intended application.

In some embodiments integration of carbon fiber and other lightweightmaterials minimizes the overall weight of the RMA 100 while retaining ahigh payload capacity. In some embodiments, the payload capacity of theRMA 100 is up to 100 lbs. at full reach and up to 150 lbs. in specificorientations. The RMA 100 is scalable for differing operations andenvironments thus a wide range of payload capacities are possible.

Support Frame

FIG. 2 depicts an embodiment of an RMA 100 housed in a support frame 10.In some embodiments, the RMA 100 fits completely within the supportframe 10 when it is fully collapsed thus increasing maneuverability ofthe system during deployment and retrieval and decreasing the storagefootprint. In some embodiments, the support frame 10 may comprise wheelsor some other such mechanism to facilitate transportation andpositioning. In some embodiments when the support frame 10 ispositioned, it may be mounted to external supports 105 to increasesystem stability during deployment of the manipulator arm. In someembodiments, the support frame 10 may provide containment for at leastone of operation, wash-down, and transportation.

Carriage

In sonic embodiments, such as the embodiment depicted in FIGS. 2A and2B, a carriage 115 may be used to couple the RMA 100 to the supportframe 10 during operations. The carriage 115 in some embodiments mayintegrate a cam path 112 and/or a rotary actuator to control thealignment of the RMA 100 as it is deployed. In some embodiments, therotary actuator is hydraulic. In some embodiments, the carriage 115 maycomprise control componentry for operation and control of the RMA 100such as electric wire rope winches, position feedback, and motors formast extension and/or rotation. In some embodiments, the carriage 115further serves the purpose of cable management.

Deployment/Retrieval

FIGS. 3A through 3H depict an embodiment of an RMA 100 deploymentprocess.

FIG. 3A depicts an RMA 100 at the beginning of deployment when theworking end of the manipulator arm has been inserted into the accesspoint. In the depicted embodiment, the access point is below the RMA100. It should be clear that in some embodiments the RMA 100 may beconfigured to deploy through access points that are in walls, ceilings,or other structures. In some embodiments, the RMA 100 may be deployed inopen environments.

FIGS. 3B through 3E depict the RMA 100 as the forearm 130 is enteringthe access point. In some embodiments, a cam and cam path may be used tocontrol the angle(s) at which the RMA 100 is deployed into the accesspoint. In the depicted embodiment, a cam and cam path are used to keepthe manipulator vertical as it enters the access point below it. In thedepicted embodiment, the carriage 115 is rotated up using a cammechanism as the forearm 130 is deployed into the access point. In thedepicted embodiment, the mast is first rotated upward to 90° (FIGS. 3Band 3C) then lowered (FIGS. 3D and 3E) to the bottom of the frame 10.

FIGS. 3F and 3G depict the RMA 100 as an elbow 140 is entering theaccess point and the carriage 115 is rotated upward another 90°. In thedepicted embodiment, the carriage 115 rotates 180° during the deploymentprocess. Once the carriage 115 is 180° from its original position themast may be deployed through the access point as depicted in FIGS. 4Aand 4B.

The RMA 100 in some embodiments utilizes a cart to facilitatetransportation and/or installation. A cart may allow the RMA 100 to belaid down on its side (horizontally) and may optionally include a barlinkage or other such mechanism to aid in moving the RMA 100 from ahorizontal to a vertical orientation and vice versa. Once in position,the optional bar linkage may be actuated to power one or more onboardhydraulic cylinders. When the frame is in the upright (vertical)position and located over the workspace, the cart may be removed.

In some embodiments, the RMA 100 frame incorporates a number of wheels,and/or one or more other mobility facilitating mechanisms, to allow theRMA 100 to be transported and positioned. The RMA 100 may be manuallypositioned or positioned using remote control. In some embodiments, theinstallation cart may comprise one or more drive mechanisms to allow forremote operation of the cart for proper positioning.

In some embodiments, the RMA 100 may be mounted to pre-existinginfrastructure, or other supports, to increase stability duringdeployment of the manipulator. In some embodiments, the RMA 100comprises a mounting plate which may be secured to existinginfrastructure. For example, the mounting plate may be secured to thefloor for a floor access point such that the load path is directedthrough the mounting plate to the floor rather than through the frame.

For deployment, the manipulator in some embodiments may use an overheadA-frame gantry beam and chain falls or other lifting mechanism. The RMA100 may be unfolded into an access point either while powered orunpowered. Some embodiments comprise a cam and cam path for controllingmotion of deployment for difficult access points. In some embodiments,during deployment, the RMA 100 carriage may follow a specific cam pathallowing the manipulator to travel linearly into an access point.

Mast

FIG. 4A depicts an embodiment of the mast 120 in a retracted position.In some embodiments, the mast 120 may comprise one or more telescopingtubes. The mast 120 in some embodiments may be extended or retracteddepending on the desired depth/height as shown in FIG. 4B. In someembodiments one or more tubes are formed from light material such ascarbon fiber. In some embodiments one or more tubes are composed ofmetal such as stainless steel. To allow for mast 120 rotation theoutermost tube may be coupled to a gear or slewing ring that may bedriven by a motor, in some embodiments. The mast 120 may be securelymounted to the carriage 115 by means of mounting rings and bearingscoupled to the outermost tube. In some embodiments, the mast 120 iscapable of rotating 360°. In some embodiments, the innermost tube maycomprise a hydraulic cylinder which may form or couple to an elbowmechanism. In the depicted embodiment, the hydraulic cylinder isdouble-acting.

Elbow

FIG. 5 depicts an embodiment of the elbow 140 which may be used tocouple a mast 120 to a forearm 130. In some embodiments, the elbow 140is a two-stage actuation. In some embodiments, the elbow 140 allows fora total of −10° to +180° of motion from vertically down. In someembodiments, the mast-elbow pivot 141 of the elbow allows for 90° ofmotion to allow the elbow linkage to be oriented down or horizontal. Insome embodiments, the forearm-elbow pivot 142 allows for 100° of motion,for instance −10° to +90° of actuation.

FIG. 6A depicts an embodiment of the elbow 140 oriented directlydownwards. FIG. 6B shows a 90° actuation of the mast-elbow pivot 141lifting the forearm 130 to a horizontal position. FIG. 6C shows anexample 90° actuation of the forearm-elbow pivot 142 that lifts theforearm 130 to a vertical position. The combination of these actuationsmay allow the RMA 100 to reach the full extents of the workspace. Insome embodiments, each stage is actuated using a single hydrauliccylinder, and each pivot pin incorporates a resolver for positionfeedback. In some embodiments, stage actuation may require multiplehydraulic cylinders.

In some embodiments, a double-acting hydraulic cylinder is mountedwithin the inner-mast 120 and provides pivot motion for a first elbowjoint 141. The hydraulic cylinder assembly may comprise astainless-steel rod and cylinder weldment. In some embodiments, thehydraulic cylinder may attach to the end of the mast 120 by means of apin.

The RMA 100 may comprise one or more joints. In some embodiments, allthe joints actuate in the same plane. The joints in some embodiments maybe offset to actuate in different planes or at different angles withrespect to each other. Different joint types with different ranges ofmotion may be implemented, such as ball joints and chain joints. Chainjoints are described in co-pending patent application entitled Systemsand Methods for Chain Joint Cable Routing, Ser. No. 14/975,544 filedDec. 18, 2015, with a priority date of Dec. 19, 2014, which is herebyincorporated by reference in its entirety. In some embodiments one ormore of the joints may be hydraulically actuated.

Forearm

In some embodiments, the forearm 130 is similar in design to the mast.In some embodiments, the forearm 130 comprises one or more telescopingtubes. In some embodiments, the one or more tubes may be composed ofcarbon fiber. In some embodiments one or more tubes is composed of metalsuch as stainless steel. FIG. 7A depicts the forearm 130 in a retractedposition and FIG. 7B depicts the forearm 130 in an extended position.The telescoping forearm 130 may extend and retract using one or morehydraulic cylinders which may be ported together to allow them toactuate at the same time, in some embodiments. The cylinder rods may behollow to minimize the number of hydraulic lines required to run throughthe forearm 130. In some embodiments, the forearm pivot actuation isprovided by one or more elbows.

In some telescoping embodiments, bushings may be utilized to preventrotation of the mast and/or forearm tubes with respect to each other. Insome embodiments, the tubes may be equipped with dual keys and matchingkey slots in the bushings to keep the sections from rotatingindependently. In some embodiments, the bushings may have slots machinedinto them to allow wash-down water to flow through. Hard stops may beincorporated into one or more of the tubes to prevent over-extension orover-retraction. In some embodiments, retraction hard stops screw intothe top of each keyway. In some embodiments, one or more interfacesbetween telescoping tools and other componentry may be coated orcomprised of low friction material to facilitate motion.

In some embodiments, the telescoping mast and/or forearm may extendusing gravity. In some embodiments, the mast and/or forearm may beretracted using a rope, tether, or other flexible attachment which maybe connected to a winch or hoist mechanism. In some embodiments, theretraction may be effected using one or more electrically driven wirerope hoists. The mast and/or forearm in some embodiments include one ormore redundant wire rope hoists for failure recovery. Each hoist may becapable of retraction on its own in the case another fails. Wire ropehoists may position the mast and/or forearm, along its stroke, asdesired by the operator.

Wrist

In some embodiments, the RMA 100 comprises a wrist joint 150 at theworking end of the forearm 130. FIG. 8A through 8C depict an examplerange of motion of the wrist 150. The wrist 150 in some embodiments maybe capable of one or more actuations including a wrist pitch and a wristroll. In some embodiments, the wrist 150 may comprise one or more rotaryactuators that enable wrist roll and pitch. The wrist pitch may beactuated using a hydraulic rotary actuator for +90° of motion in thevertical plane, in some embodiments. The wrist roll may utilize ahydraulic rotary actuator and is capable of 180° of rotation, in someembodiments. In some embodiments, each joint in the wrist 150 is capableof up to 180° of rotation. In some embodiments, the wrist 150 comprisesa master tool changer assembly. In some embodiments, the wrist 150 maycomprise a universal grip or other mechanism to allow for deployment ofa variety of tools and/or end effectors.

End Effectors

In some embodiments, to accommodate multiple end effectors in differentorientations, there is a matching interface between the end effector,forearm, or wrist and tools or other end effectors. Some embodiments mayincorporate a universal coupling mechanism between various tools and/orend effectors and the working end of the RMA. In some embodiments, thecoupling mechanism may be configured for end effector interchange. FIG.9A depicts a rear isometric view of an embodiment of a gripper 160comprising an embodiment of an end effector coupling mechanism 165 thatcan be used to connect and secure an end effector to a forearm 130. FIG.9B depicts a front isometric view of the forearm 130 comprising anembodiment of a forearm coupling mechanism 155 that couples and securesan end effector 160 to the forearm 130. In some embodiments, thecoupling mechanism is adapted for quick attach and release to allow forrapid end effector switching. In some embodiments, the couplingmechanism may comprise one or more of mechanical, electrical, andhydraulic connections. In some embodiments, the coupling mechanism maycomprise means for materials transfer into and out of the workspace suchas tubing. In some embodiments, the coupling mechanism is adapted toprovide power, control, and materials transfer capabilities for avariety of different end effectors.

FIG. 9C depicts the coupling mechanism embodiments of FIGS. 10A and 10Bwhen coupled and the wrist is bent 90° downward. FIG. 9D depicts thecoupling mechanism embodiments of FIGS. 10A and 10B when coupled and thewrist is bent 90° upward.

The working end of the forearm 130 may be equipped with one or moresensors and/or an end effector such as a gripper or tool in someembodiments. FIGS. 10A and 10B depict front and rear isometric views ofan embodiment of a gripper 160. The gripper 160 may be capable ofgrasping objects and deploying a variety of tools. In some embodiments,the jaws 161 may be coupled to a linkage 162 to ensure they remainparallel during opening and closing. In some embodiments, in the eventof a hydraulic failure, the gripper 160 may fail in its “as-is”position. If pressure is lost the jaws 161 may become compliant and ableto move if a predefined load is applied to the jaws 161. In someembodiments, a reduced stroke piston is used for smaller access pointskeeping the gripper 160 from opening to a size greater than apredetermined limit.

A gripper 160 can employ a wide variety of tools that may be used indifferent applications. In some embodiments, a gripper 160 may be usedin conjunction with another tool, end effector, and/or one or moresensors. This may be useful in instances where the gripper 160 may beused to grasp infrastructure and provide stability to the tool or otherend effector. Some embodiments may comprise other tool/endeffector/sensor configurations as needed for the desired operations.

For some applications, the end effector may be a specific tool. In someembodiments end effectors are actuated by one or more of mechanical,electro-mechanical, hydraulic, electric over hydraulic, pneumatic,magnetic, piezoelectric, and linear motor actuator.

In some embodiments, each tool or end effector comprises a mountinginterface that allows it to be grasped by a gripper 160 in one or moredifferent orientations. One such interface is shown and described inco-pending application System and Method for Inspection and Maintenanceof Hazardous Spaces, Ser. No. 15/341,985 filed Nov. 2, 2016, with apriority date of Nov. 3, 2015, which is hereby incorporated by referencein its entirety.

Tools

The RMA 100 can perform a multitude of different operations by deployinga variety of different tools and end effectors. The tools deployed bythe RMA 100 may comprise off-the-shelf tools that may be modified forremote deployment, in some embodiments. The RMA 100 may comprise any oneor more of waterjet tool, inflatable bag tool, grout tool, shear tool,educator bulk retrieval tool, jet wash tool, scoop/scraper tool,swabbing tool, gamma monitor, and other tools, end effectors, andsensors for carrying out one or more of inspection, maintenance,repairs, and cleaning. A number of other tools are possible includingsimple tools such as rake, trowel, shovel, and the like.

FIGS. 11A through 11C depict an embodiment of a tool changing process.The end effector 160 is inserted under the RMA 100 with the use of atool handling system 210. In this embodiment, the end effector 160 isplaced in-line with the retracted forearm 130. As the mast 120 and/orthe forearm 130 are extended, the wrist coupling mechanism 155 isengaged to the end effector coupling mechanism 165 and secures the endeffector 160 to the forearm 130. FIG. 12 shows an embodiment of the RMA100 coupled to an end effector 160. FIG. 13 depicts an isometric view ofthe end effector 160 and forearm 130 coupled with a waterjet tool 180.

In some embodiments, the tooling may be deployed into the workspacethrough separate access points which may be offset from the primaryaccess point. In some embodiments, additional tools or end effectors maybe placed in the workspace prior to RMA entry. In some embodiments, thetools and end effectors may be changed outside of the workspace.

Tools and end effectors may be lowered into the workspace using a hoistand/or pulley system embodiments. In some embodiments once a tool or endeffector is secured to the RMA 100 using a wire rope, or other suchconnector, may be tensioned and retracted by the RMA 100 as needed. Awire rope, or other such connector, may be used to retrieve the endeffector. A wire rope, or other such connector, may be wound on a springtensioned spool, which may be motorized and/or manual. A spring reel maybe provided in several tension ranges to adapt to various tool or endeffector weights.

Hydraulic Power Unit

In some embodiments, the RMA comprises one or more hydraulic power units(HPU) to provide motive power for one or more hydraulic actuators. Insome embodiments, hydraulic actuators include one or more of: elbowpivots, forearm extend, wrist pitch, wrist roll, and gripper open/close,among other things.

In some embodiments, an HPU may be controlled automatically by thecontrol system during operations. The control system may automaticallyactivate the hydraulic services upon a hydraulic service demand, andautomatically control the HPU cooling system per hydraulic fluidtemperature, in some embodiments. An HPU may include basic manualcontrols, in addition to the automatic controls, for flexible control asneeded. In some embodiments, local manual control for the HPU may beprovided to allow for recovery in case of a control system failure.

In an example embodiment, the HPU supplies hydraulic oil to all thehydraulic actuators at a maximum pressure of 2.9 ksi and a maximum flowrate of 3.96 gallons per minute. Other pressures and flow rates arepossible. In some embodiments, hydraulic fluid levels may be monitoredto detect leakage.

Wash-Down

In some embodiments, the RMA comprises an integrated wash-down systemthat is designed to remove contaminants from the RMA. In someembodiments wash-down occurs as the RMA is being retracted from theworkspace thus capturing contaminants within the workspace. In someembodiments, the wash-down system may comprise one or more separate washrings located within the RMA which allow pressurized water to be sprayedonto the RMA surfaces. Some embodiments incorporate three wash ringswherein one is located at the top of the mast, one is located at thebottom of the mast, and one is located inside the forearm. Duringretrieval, each of the wash rings may be pressurized in a series ofsteps to ensure full cleaning of all components, in some embodiments. Insome embodiments, a high-pressure water supply may be used to run thewash-down system.

In some embodiments, at least some of the electrical componentry may beheld to ingress protection (IP) 64 or higher to protect againstoverspray and fluids in the workspace. In some embodiments, alloverspray and overflow may be captured by support frame containmentcovers and may drain from the bottom of a wash pan into the workspace.In the event of a drain blockage a float may automatically shut off thewash water in some embodiments.

Cable Management

Cables may run at least one of internally and externally the RMA. Theterm “cable” is intended to comprise electrical wiring, hydraulic hoses,pneumatic hoses, fiber optic cable, communications cable, or any othercables, wires, or lines as well as bundles thereof. The cables may beused to transfer/transmit data pertaining to sensing and/or control inthe system or any extensions attached to the system. Additionally,cables may be included for materials transfer into and out of theworkspace.

One or more services, in some embodiments, may be routed internallythrough one or more of the mast, elbow, and forearm. In some embodimentscable management may be accomplished using one or more of an externaltensioned reel system, block-and-tackle system, and an internal cablechain. A block-and-tackle system may be under constant tension usingsystems such as constant force gas springs in some embodiments. In someembodiments, additional umbilical cables may be included for toolsrequiring separate power or control systems or additional sensor orsignaling cables. The cable management system may allow cables to befeed in and out of the mast during extension and retraction, in someembodiments. This may be accomplished using a set of pulleys that may betensioned with pneumatic cylinders, in some embodiments. Someembodiments may comprise one or more cable shrouds to prevent lines andcables from being pinched during actuation.

An embodiment of a cable management system for the RMA may incorporate aRolaTube® attached to a tether in proximity to the RMA similarly to thedeployment retrieval tool disclosed in co-pending application System andMethod for Inspection and Maintenance of Hazardous Spaces, Ser. No.15/341,985 filed Nov. 2, 2016, with a priority date of Nov. 3, 2015,which is hereby incorporated by reference in its entirety. Someembodiments may comprise and support a tether containing services andmaterial transfer lines between sections. This may reduce forcesrequired for tether movement and prevent entanglement with internalinfrastructure in the workspace.

In some embodiments one or more sensors or other devices may utilizewireless communication technologies such near field communication (NFC)and Bluetooth, among others. Wireless sensors and other devices mayreduce the amount of cabling required thus increasing range, capability,and mobility of the system.

Sensing and Control

Control of the RMA is initiated by a control system. The control systemmay be one of local and remote to the RMA and the operating space.Monitoring and control operations may be performed locally, remotely,and/or may be mobile. Mobile monitoring and control may be implementedusing one or more mobile devices such as smart phones, laptops, moveabledesktop computer work stations, tablets, and wearable computing devices.In some embodiments one or more operators may be equipped with one ormore wearable devices, or other mobile devices, that provide feedback tothe operator(s). For instance, a vibration and/or audible alert may beused to provide warnings to an operator.

In some embodiments control may be affected using a master-slavemanipulation system including a “man-in-the-loop” system. In suchembodiments, an operator may control a master system that is remote tothe workspace. As the operator moves and controls the master system, theslave system (the RMA) may respond instantly and exactly. One or moresensors located at least one of in the workspace and on the RMA mayprovide feedback to the operator. In some embodiments, one or moresensors on the RMA may provide haptic and other feedback to the operatorto simulate any resistance or other forces acting on the RMA. In someembodiments, the RMA may not respond if the master directs it to performa task that is not possible or will damage the RMA or the workspace. Forinstance, if the master directs the RMA to move outside of its range ofmotion or the extents of the workspace, it may move to the extent of itsrange of motion or the workspace and no further. Some embodiments mayincorporate additional safety mechanisms such as the slave notresponding if the master is moved too rapidly. In some embodiments, themaster system is an exact replica, which may be scaled in size, of theslave system. In some embodiments, the master system is wearable, forinstance on an operator's arm.

In some embodiments, a preliminary inspection is performed prior toengaging in other operations. Preliminary inspections may yield datathat may be used to pre-program the RMA. To perform operationsautomatically. In some embodiments, operators may program an otherwisepredetermined set of data into the RMA to perform operationsautomatically. In some embodiments, the workspaces) may be inspectedafter operations for quality control or other purposes. The controls forthe end effectors and/or tools may be integrated into the controls forthe RMA and/or standalone.

Virtual Barriers

In some embodiments, the operating space may be scanned using one ormore sensors prior to operations to gather data which may be used togenerate an electronic three-dimensional map of the operating space.When more than one sensor is used to gather data about the geometry ofthe operating space the data may be combined using known in the artsensor fusion techniques. Alternatively, or additionally, thethree-dimensional map of the operating space may be manually generatedusing known information about the geometry of the space.

In some embodiments, the three-dimensional map may be visible to theoperator on a user interface and/or stored in memory. The operator mayset a global coordinate system and one or more local coordinate systemswithin the space. The purpose of a three-dimensional map of theoperating space is to define the boundaries of the operating space andany infrastructure or objects in the space that may restrict the RMA'srange of motion in the space. Knowledge of the geometry of the operatingspace may be used to pre-program the RMA to carry out operationsautomatically within the space and to avoid impact with objects in thespace when carrying out operations manually.

One or more virtual barriers may be generated to prevent equipment fromcontacting surfaces and/or objects in the operating space to protect theintegrity of both the RMA and the operating space. A three-dimensionalmap of the operating space defines the actual physical boundaries of theoperating space. Virtual barriers define one more virtual operatingzones, offset from the physical boundaries, in which operations may besafely carried out in the operating space without damage to the space orto the RMA. Virtual barriers are invisible “walls” generated eitherautomatically by the control system using predetermined offset valuesand/or manually programmed or edited by an operator. Virtual barrieroffset(s) may be programmed in a similar fashion as one would programthe area of operations for a CNC machine.

An example virtual barrier embodiment is depicted in FIG. 14. In someembodiments, an impermeable virtual barrier 905 may be offset from oneor more of the surfaces 900 a,b in the operating space 950 and may serveto prevent the RMA from advancing any closer to the one or more surfaces900 a,b. In some embodiments, an impermeable virtual barrier 905 may beset at a minimum allowable distance from the one or more surfaces 900a,b at which operations may be safely performed. In the depictedembodiment virtual barriers are offset from a wall 900 a and an object900 b in the operating space 950. In some embodiments, a permeablevirtual barrier 915 may be offset from an impermeable virtual barrier905 or from one or more surfaces 900 a,b in the operating space 950 andmay serve to provide haptic feedback and/or a warning to an operatorwhen encountered. The warning may be one of haptic, audial, and/orvisual. In some embodiments, the warning may increase in intensity asthe RMA, moves farther into the permeable virtual barrier 915.

In some embodiments, the haptic feedback may be in the form ofresistance. For instance, as the RMA traverses through the permeablevirtual barrier 915 the resistance may increase until the RMA encounterseither an impermeable virtual barrier 905 or the resistance isinsurmountable. In some embodiments one or more virtual barriers may begenerated automatically using predetermined values and/or manuallygenerated by an operator. The offsets of the virtual barriers fromsurfaces and each other may be uniform throughout or variable. In thedepicted embodiment the virtual barriers are offset farther from theobject 900 b than from the wall 900 a. The one or more virtual barriersmay be visible on a display.

Interface

An embodiment of the control system 1000 is depicted in FIG. 15. The RMA100 may comprise one or more sensors 1700, one or more actuators 1730,one or more transceivers 1745, and a control system 1000. The controlsystem 1000 may comprise one or more processors 1710, one or more userinterfaces 1720, one or more transceivers 1740, one or more programmablecontrollers 1750, a memory 1760, and one or more remote control stations1770. A programmable controller 1750 provides for a flexible means ofmanipulation of the RMA 100 and/or tools allowing for a best-fit controlsolution for the equipment. The one or more remote control stations 1770may provide custom operator interfaces. The one or more interfaces 1720may comprise one or more of displays, touchscreens, joysticks, buttons,toggles, switches, and voice input for equipment control. In someembodiments, the interface 1720 may be projected such that an operatormay operate the RMA from inside a virtual 3D map of the operating space.

More detail on possible control system and actuator embodiments isdescribed in Systems and Methods for Chain Joint Cable Routing, Ser. No.14/975,544 filed Dec. 18, 2015, with a priority date of Dec. 29, 2014,which is hereby incorporated by reference in its entirety.

In some embodiments, the control system may require one or more forms ofauthentication from the operator in order to function. In someembodiments, if the control system loses confidence that an operator isproperly authenticated, such as if it has not been tasked within apredetermined period, it may require the operator to re-authenticate.

Modes of Operation

In some embodiments, control methods may comprise one or more ofjoint-by-joint actuation and inverse kinematic actuation. Inversekinematics allows an operator to control the gripper/tool position, andthe control system determines the joint movements to achieve thatposition. In some embodiments control is operator-initiated individualvariable speed joint control. In some embodiments, joint control may beeither push-and-hold type or bump time-based type depending on theoperation being performed.

In some embodiments, the control system 1000 may comprise a flexible androbust control interface. The interface may comprise two or more modesof control providing appropriate control for the various normal andpotential off normal operations of the equipment. The primary designconstraint that provides the ability for the control system 1000 topotentially perform various high level functions may be the integratedposition feedback on the RMA axes. With the information of the RMAconfiguration, the control system can perform inverse kinematic andkinematic calculations. Two basic modes of operation for the controlsystem are joint control mode and inverse kinematic control mode.

In some embodiments, joint control mode may provide an open-loop controlfor a singular axis. An operator may select the desired axis to controlon a control interface. Control for the selected axis may be provided bya joystick, or other input device and/or interface. Joint control modemay be used during recovery operations, calibration operations, andoff-normal operations where the inverse kinematic control hinders theoperator ability to perform a task. Open loop joint control mode allowsthe removal of the RMA in the event of a position sensor failure.

In some embodiments, closed-loop inverse kinematic control mode mayprovide simultaneous x/y/z control of a tool/end effecter to theoperator. Inverse kinematic control allows an operator to control theorientation of a tool/end effector relative to the floor, or other fixedinfrastructure in the workspace, and allows the operator to control theposition of the tool/end effector (Cartesian coordinate frames) insidethe workspace.

The RMA and tools may be manually or automatically operated. In someembodiments, some functions are automatic and some are manual. The RMAin some embodiments may offer variable speed control for each joint,with an overall adjustable maximum speed.

Interlocks

In some embodiments, the RMA may comprise one or more interlocks toensure efficient, proper, and safe equipment operations. In someembodiments, these interlocks vary in seriousness and indicatedawareness to the operator. In some embodiments, there are three types ofinterlocks comprising alarms, warnings, and operational.

In some embodiments alarms may stop system operations that may riskequipment health and may generally cause some sort of display, haptic,and/or auditory feedback to an operator. The control system alarm may bevisually displayed on an interface and status of the system alarmsprovided, in some embodiments. In some embodiments alarms may requireoperator acknowledgement and resolution before the system can becomeoperational again. In some embodiments, alarms may remain active andnon-resettable if the existing alarm condition is active.

In some embodiments warnings may comprise display, haptic, and/orauditory feedback to an operator but may not cause the RMA to suspendoperations. Operational interlocks may be performed by the controlsystem to ensure proper equipment health during normal operations. Insome embodiments, operational interlocks may not be identified to anoperator and are typically performed in the background. For example, ahydraulic power unit may integrate a cooling interlock thatactivates/deactivates a fan depending on the fluid temperature. Thisinterlock may occur in the normal operating logic of the system.

The control system may provide equipment interlocks as necessary (whenconsidering desired control options and equipment feedback) to improveequipment health and operations. In some embodiments, control systeminterlocks may be segregated into three primary levels:

Equipment Enable Interlock—An interlock for healthy operations for alloperations (e.g., emergency stop)

Equipment Normal Operations Interlock—An interlock for normal operationsbut is potentially not required for off normal operations (e.g.,hydraulic level low)

Equipment Operation Specific Interlock—An interlock for a specific suboperation (e.g., during initial deployment operations locking thegripper in closed position during deployment)

In some embodiments, the control system may include an emergency stopsystem that removes all motive power from the equipment once tripped. Insome embodiments, the emergency stop system does not remove power fromthe control and monitoring equipment. In some embodiments, an emergencystop system allow for operational feedback during the emergency stopcondition. After an emergency stop, the system may need to be reset byan operator to be functional. Although the equipment may stop or shutdown, the control system may remain operational in some embodiments,which allows for alerts to occur and troubleshooting actions. Thecontrol system design in some embodiments provides electrical disconnectswitches at electrical service input points to allow for equipmentisolation. The control system meets electrical standards to ensureequipment safety, and allows the electrical hydraulic, and mechanicalcomponents to fail to a safe state upon the loss of services.

Sensors

In some embodiments, the RMA 100 may comprise one or more sensors. Theone or more sensors may comprise one or more of contact sensors,non-contact sensors, capacitive sensors, inductive sensors, 3D imagers,cameras, thermal imagers, thermometers, pressure sensors,accelerometers, inertial measurement units (MU), rotary encoders,resolvers, string encoders, radiation detectors, LIDAR, microphones,force sensors, load sensors, and strain sensors, among others. In someembodiments, one or more sensors may be used to determine the positionof the deployed tools during operations. In some embodiments, one ormore sensors may be used to monitor at least one of strain, torque,pressure, and environmental conditions at one or more locations in thesystem as a safety mechanism to prevent catastrophic failures.

In some embodiments, the RMA 100 may include one or more imagingsensors. The one or more imaging sensors may comprise one or more of 3Dimaging, 2D range sensor, camera, thermal imager, and radiationdetector, among others. One or more imaging sensors may be used toprovide inspection and monitoring capabilities for remote operators.Signals from one or more imaging sensors may be displayed in real-time,recorded for later review, and/or recorded for operational records. Insome embodiments one or more imagers may be mounted to, or in proximityto, an end effector to allow a close-up view of operations. In someembodiments one or more imagers may be mounted in the workspace. Any oneor more of the imagers may be one of fixed or pan-tilt-zoom types. Anyone or more of the imagers may be controlled remotely by an operator orpreset to follow input movement patterns or rules.

The operator may select and manage desired imager views for operations,controlling the imagers with associated control features such as thepan, tilt, zoom (PTZ), focus, and lights. In some embodiments, one ormore imagers may provide complete visual coverage of operations in theworkspace. One or more imagers may be used for visual collisionavoidance during operations. Audio feedback to the operators may beprovided from any one or more locations in the workspace and/or from oneor more locations on the RMA 100.

One or more sensors may be included in the RMA 100 to detect contactwith infrastructure and/or other surfaces in the workspace. In someembodiments, one or more sensors may be a six-axis sensor capable ofrelaying the direction and magnitude of an impact back to an operatorand/or other personnel. In some embodiments one or more sensors mayserve as a proximity warning system to prevent contact withinfrastructure and/or other surfaces in the workspace. In someembodiments, the control system will not process inputs that may damagethe equipment or the workspace.

In some embodiments extension and/or velocity of extendable componentsin the system, such as the forearm and/or mast, may be measured usingone or more string potentiometers. The mast rotate may be operated by anelectric geared motor attached to a turntable bearing and use a resolverfor position feedback, in some embodiments, lighting may be provided atone or more locations in the workspace and/or at each imager position.

In some embodiments, such as the embodiment depicted in FIG. 16, the RMA100 comprises a dynamic measurement unit 101.0 wherein the dynamicmeasurement unit 1010 comprises one or more accelerometers and one ormore rate sensors. In some embodiments, the RMA 100 comprises one ormore non-contact sensors affixed to at least one of the forearm 130,mast, and elbow. In the depicted embodiment a non-contact sensor iscollocated with the dynamic measurement unit 1010 on the forearm 130. Adynamic measurement unit 1010 may be configured as a six degree offreedom three axis sensor configured to operate in a Cartesiancoordinate system. In some embodiments, the dynamic measurement unit1010 comprises three accelerometers and three rate sensors where theaccelerometers and rate sensors are paired and each pair is orientedalong each axis in a Cartesian coordinate system.

In some embodiments, one or more non-contact sensors (not depicted)affixed to at least one of the forearm 130, mast, and elbow reportobject measurements in the operating space in a polar reference frame,as range and azimuth or bearing to an object and/or surface. Thecontroller 1000 in some embodiments computes and displays the objectsand/or surfaces in the operating space in a Cartesian reference frame ofx, y, and z. This is done for the operator to present a more intuitiveview of the operating space in three dimensions so it is it is easier tounderstand and visualize. Therefore, in some embodiments, thenon-contact sensor data will be converted to the Cartesian referenceframe before it is used.

The standard conversion from the polar to the Cartesian reference frameis:x _(m) =r _(m) cos θ_(m) and y _(m) =r _(m) sin θ_(m),  (1)

where r_(m) and θ_(m) are the range and bearing, respectively, of thesensor target in the polar reference frame and x_(m) and y_(m) are thedownrange and cross range coordinates, respectively, in the convertedCartesian reference frame. However, when dealing with the statistics ofthe measurements, mean and variance, one cannot use the above equationsto directly transform from the polar to the Cartesian frames.

However, if there is concern regarding the uncertainty of themeasurements in terms of variance in the range and the bearingmeasurements, additional steps must be considered in the translation. Inthe case of variance during the conversion, the standard conversion willnot generate a perfect ellipsoid of the error envelop. In order to do sothere may be debiased correction term subtracted from (Equation 1) toget a better value for the range and bearing measurements.

Debiasing the standard conversion is generally well understood in theart, and is well published and described. The following equations givethe debiased conversion from a polar coordinate frame to a Cartesianreference frame:x ^(dc) =r _(m) cos θ_(m) −E[{tilde over (x)}|r _(m),θ_(m)],  (2)y ^(dc) =r _(m) sin θ_(m) −E[{tilde over (y)}|r _(m),θ_(m)],  (3)where x^(dc) and y^(dc) are the final downrange and cross range debiasedconversion coordinates of the sensor target and

$\begin{matrix}{{{E\left\lbrack {{\overset{\sim}{x}❘r_{m}},\theta_{m}} \right\rbrack} = {r_{m}\cos\;{\theta_{m}\left( e^{- {e\;}^{\frac{2}{\theta/}2}} \right)}}},} & (4) \\{{{E\left\lceil {r_{m},\theta_{m}} \right\rceil} = {r_{m}\sin\;{\theta_{m}\left( {e^{\sigma\frac{2}{\theta}} - e^{\sigma\;{\frac{2}{\theta}/2}}} \right)}}},} & (5)\end{matrix}$

The covariance matrix, R_(a), for the downrange and cross rangecoordinates are

$\begin{matrix}{R_{\alpha}^{11} = {{{var}\left( {{\overset{\sim}{x}❘r_{m}},\theta_{m}} \right)} = {{r_{m}^{2_{e^{{- 2}\sigma\; g^{2}}}}\left\lbrack {{\cos^{2}{\theta_{m}\left( {\cos\mspace{14mu} h\mspace{11mu} 2_{\sigma_{\theta}}^{2 -}\cos\mspace{14mu} h_{2}\sigma_{\theta}^{2}} \right)}} + {\sin^{2}{\theta_{m}\left( {{\sin\mspace{11mu} h\mspace{14mu} 2\sigma_{\theta}^{2}} - {\sin\mspace{14mu} h\mspace{14mu}\sigma_{\theta}^{2}}} \right)}}} \right\rbrack} + {\sigma_{r}^{2}{e^{- 2_{\sigma\theta}}\left\lbrack {{\cos^{2}{\theta_{m}\left( {{\cos\mspace{14mu} h\mspace{14mu}\sigma_{\theta}^{2}} - {\cos\mspace{14mu} h\mspace{14mu}\sigma_{\theta}^{2}}} \right)}} + {\sin^{2}{\theta_{m}\left( {\sin\mspace{14mu} h\mspace{14mu} 2_{\sigma_{\theta}}^{2}} \right)}}} \right\rbrack}}}}} & (6) \\{{R^{22} = {{{var}\left( {{\overset{\sim}{x}❘r_{m}},\theta_{m}} \right)} = {{r_{m}^{2_{e^{{- 2}\sigma\; g^{2}}}}\left\lbrack {{\sin^{2}{\theta_{m}\left( {\cos\mspace{14mu} h\mspace{14mu}\sigma_{\theta}^{{- {co}}\; s}h\;\sigma_{\theta}^{2}} \right)}} + {\cos^{2}{\theta_{m}\left( {{\sin\mspace{14mu} h\mspace{14mu} 2\sigma_{\theta}^{2}} - {\sin\mspace{14mu} h\mspace{14mu}\sigma_{\theta}^{2}}} \right)}}} \right\rbrack} + {\sigma_{r}^{2_{e -}}2{\alpha^{\theta^{2}}\left\lbrack {{\sin^{2}{\theta_{m}\left( {{2\mspace{14mu}\cos\mspace{14mu} h\mspace{14mu} 2\sigma_{\theta}^{2}} - {\cos\mspace{14mu} h\mspace{14mu}\sigma_{\theta}^{2}}} \right)}} + {\cos^{2}{\theta_{m}\left( {{2\sin\mspace{14mu} h\mspace{14mu}\sigma_{\theta}^{2}} - {\sin\mspace{14mu} h\mspace{14mu}\sigma_{\theta}^{2}}} \right)}}} \right\rbrack}}}}},} & (7) \\{\mspace{79mu}{R_{\alpha}^{12} = {{cov}\left( {\overset{\sim}{x}\overset{\sim}{y}{{r_{m},{\theta_{m}{e^{{- 4}{\sigma\theta}^{2}}\left\lbrack {\sigma_{r}^{2} + {\left( {r_{m}^{2} + \sigma_{r}^{2}} \right)\left( {1 - e^{{\sigma\theta}^{2}}} \right)}} \right\rbrack}}}}} \right.}}} & (8)\end{matrix}$

where σ_(r) ² and σ_(θ) ² are the variances of the range and bearing,respectively, in the sensor polar reference frame.

Equipment Power-Up

Upon the application of electrical services, the control system maypower up in an equipment motive safe state in some embodiments. With theelectrical services provided, the start-up of the equipment control mayrequire operator initiation or emergency stop system reset and alarmreset at the operator interface. Operator initiation of the system mayensure that personnel are aware of the equipment status and state priorto operations.

Equipment Shutdown

In some embodiments, the control system may allow for the equipment tobe shut down in a motive-safe state by the triggering of an emergencystop circuit, The design of the control system in some embodimentsensures the equipment fails in a safe state upon the removal of motivepower by emergency stop circuit or removal of electrical services. Anon-powered fail-safe design allows for a hard equipment shutdown, suchas an electrical disconnect and isolation.

Recovery

In some embodiments, the control system may provide an off normaloperations mode for recovery operations in the event of a failure.Equipment recovery through the user interface may be the primary mode ofequipment recovery for difficult to access operating areas. If theequipment cannot be recovered through the user interface (e.g., if theprogrammable controller failed), the operator may then implement ahydraulic or manual mechanical means for recovery.

Non-Transitory Computer Readable Medium

The various operations of methods described above may be performed byany suitable means capable of performing the operations, such as varioushardware and/or software component(s), circuits, and/or module(s).Generally, any operations illustrated in the Figures may be performed bycorresponding functional means capable of performing the operations.

The various illustrative logical blocks, modules and circuits describedin the present disclosure may be implemented or performed with ageneral-purpose processor, a digital signal processor (DSP), anapplication specific integrated circuit (ASIC), a field programmablegate array signal (FPGA) or other programmable logic device PLD),discrete gate or transistor, discrete hardware components or anycombination thereof designed to perform the functions described herein.A general-purpose processor may be a microprocessor, but in thealternative, the processor may be any commercially available processor,controller, microcontroller or state machine. A processor may also beimplemented as a combination of two computing components, e.g., acombination of a DSP and a microprocessor, a plurality ofmicroprocessors, one or more microprocessors in conjunction with a DSPcore, or any other such configuration.

In one or more aspects, the functions described may be implemented inhardware, software, firmware, or any combination thereof. If implementedin software, the functions may be stored on or transmitted over as oneor more instructions or code on a computer-readable medium.Computer-readable media includes both computer storage media andcommunication media including any medium that facilitates transfer of acomputer program from one place to another. A storage media may be anyavailable media that can be accessed by a computer. By way of example,and not limitation, such computer-readable media can comprise RAM, ROM,EEPROM, CD-ROM or other optical disk storage, magnetic disk storage orother magnetic storage devices, or any other medium that can be used tocarry or store desired program code in the form of instructions or datastructures and that can be accessed by a computer. Also, any connectionis properly termed a computer-readable medium. For example, if thesoftware is transmitted from a website, server, or other remote sourceusing a coaxial cable, fiber optic cable, twisted pair, digitalsubscriber line (DSL), or wireless technologies such as infrared, radio,and microwave, then the coaxial cable, fiber optic cable, twisted pair,DSL, or wireless technologies such as infrared, radio, and microwave areincluded in the definition of medium. Disk and disc, as used herein,includes compact disc (CD), laser disc, optical disc, digital versatiledisc (DVD), floppy disk and Blu-ray disc where disks usually reproducedata magnetically, while discs reproduce data optically with lasers.Thus, in some respects, a computer readable medium may comprisenon-transitory computer readable medium (e.g., tangible media). Inaddition, in some aspects a computer readable medium may comprisetransitory computer readable medium (e.g., a signal). Combinations ofthe above should also be included within the scope of computer-readablemedia.

The methods disclosed herein comprise one or more steps or actions forachieving the described method. The method steps and/or actions may beinterchanged with one another without departing from the scope of theclaims. In other words, unless a specific order of steps or actions isspecified, the order and/or use of specific steps and/or actions may bemodified without departing from the scope of the claims. Processes orsteps described in one implementation can be suitably combined withsteps of other described implementations.

The functions described may be implemented in hardware, software,firmware or any combination thereof. If implemented in software, thefunctions may be stored as one or more instructions on acomputer-readable medium. A storage media may be any available mediathat can be accessed by a computer. By way of example, and notlimitation, such computer-readable media can comprise RAM, ROM, EEPROM,CD-ROM or other optical disk storage, magnetic disk storage or othermagnetic storage devices, or any other medium that can be used to carryor store desired program code in the form of instructions or datastructures and that can be accessed by a computer. Disk and disc, asused herein, include compact disc (CD)), laser disc, optical disc,digital versatile disc (DVD), floppy disk, and Blu-ray® disc where disksusually reproduce data magnetically, while discs reproduce dataoptically with lasers.

Thus, certain aspects may comprise a computer program product forperforming the operations presented herein. For example, such a computerprogram product may comprise a computer readable medium havinginstructions stored (and/or encoded) thereon, the instructions beingexecutable by one or more processors to perform the operations describedherein. For certain aspects, the computer program product may includepackaging material.

Software or instructions may also be transmitted over a transmissionmedium. For example, if the software is transmitted from a website,server, or other remote source using a coaxial cable, fiber optic cable,twisted pair, digital subscriber line (DSL), or wireless technologiessuch as infrared, radio, and microwave, then the coaxial cable, fiberoptic cable, twisted pair, DSL, or wireless technologies such asinfrared, radio, and microwave are included in the definition oftransmission medium.

Further, it should be appreciated that modules and/or other appropriatemeans for performing the methods and techniques described herein can bedownloaded and/or otherwise obtained by a user terminal and/or basestation as applicable. For example, such a device can be coupled to aserver to facilitate the transfer of means for performing the methodsdescribed herein. Alternatively, various methods described herein can beprovided via storage means (e.g., RAM, ROM, a physical storage mediumsuch as a compact disc (CI)) or floppy disk, etc.), such that a userterminal and/or base station can obtain the various methods uponcoupling or providing the storage means to the device.

It is to be understood that the claims are not limited to the preciseconfiguration and components illustrated above. Various modifications,changes and variations may be made in the arrangement, operation anddetails of the methods and apparatus described above without departingfrom the scope of the claims.

For the sake of convenience, the operations are described as variousinterconnected functional blocks or distinct software modules. This isnot necessary, however, and there may be cases where these functionalblocks or modules are equivalently aggregated into a single logicdevice, program or operation with unclear boundaries. In any event, thefunctional blocks and software modules or described features can beimplemented by themselves, or in combination with other operations ineither hardware or software.

Having described and illustrated the principles of the systems, methods,processes, and/or apparatuses disclosed herein in a preferred embodimentthereof, it should be apparent that the systems, methods, processes,and/or apparatuses may be modified in arrangement and detail withoutdeparting from such principles. Claim is made to all modifications andvariation coming within the spirit and scope of the following claims.

What is claimed is:
 1. A robotic arm control system, comprising: arobotic arm configured to deploy one or more tools in an operatingspace; one or more sensors; and a control system operably configured to:identify one or more surfaces defining the operating space with the oneor more sensors, generate a three-dimensional map of the operating spacebased at least in part on the one or more surfaces defining theoperating space, establish an impermeable virtual barrier offset fromone or more surfaces in the operating space, wherein the impermeablevirtual barrier offset is at least one of variable or uniform, andestablish a permeable virtual barrier offset from the impermeablevirtual barrier.
 2. The system of claim 1, wherein the impermeablevirtual barrier offset is a minimum allowable distance in whichoperations may be performed.
 3. The system of claim 1, wherein theimpermeable virtual barrier prevents the robotic arm from advancingbeyond the impermeable virtual barrier.
 4. The system of claim 1,wherein the permeable virtual barrier, when encountered, generates atleast one of a warning and haptic feedback to an operator.
 5. The systemof claim 4, wherein the haptic feedback is in the form of resistance. 6.The system of claim 5, wherein the resistance increases as the roboticarm approaches the impermeable virtual barrier.
 7. The system of claim1, wherein the control system is configured to allow an operator toremotely control the robotic arm.
 8. The system of claim 1, wherein theone or more sensors are carried by the robotic arm.
 9. The system ofclaim 1, wherein the control system is further operably configured tocombine data received from the one or more sensors.
 10. A method ofcontrolling a robotic arm, the method comprising: providing a roboticarm configured to deploy one or more tools in an operating space;identifying one or more surfaces defining the operating space with oneor more sensors; receiving signals from the one or more sensorsindicative of geometry of the operating space; establishing animpermeable virtual barrier based at least in part upon the signalsoffset from the one or more surfaces defining the operating space,wherein the impermeable virtual barrier offset is at least one ofvariable or uniform; and establishing a permeable virtual barrier offsetfrom the impermeable virtual barrier.
 11. The method of claim 10,wherein establishing the impermeable virtual barrier includesestablishing an impermeable virtual barrier that is offset from the oneor more surfaces by a minimum allowable distance in which operations ofthe robotic arm may be performed in the operating space.
 12. The methodof claim 10, further comprising limiting the robotic arm from advancingbeyond the impermeable virtual barrier.
 13. The method of claim 10,further comprising generating a warning to an operator when the roboticarm encounters the permeable virtual barrier.
 14. The method of claim13, wherein the warning comprises haptic feedback.
 15. The method ofclaim 14, further comprising increasing resistance to control therobotic arm in at least one manner when the robotic arm encounters thepermeable virtual barrier.
 16. The method of claim 15, furthercomprising further increasing resistance to control the robotic arm inthe at least one manner when the robotic arm has passed the permeablevirtual barrier and approaches the impermeable virtual barrier.
 17. Themethod of claim 10, wherein the one or more sensors are carried by therobotic arm.
 18. The method of claim 10, further comprising generating athree-dimensional map of the operating space based at least in part uponthe signals from the one or more sensors.
 19. A robotic arm controlsystem, comprising: a robotic arm configured to deploy one or more toolsin an operating space; one or more sensors; and a control systemoperably configured to: identify a surface defining the operating spacebased at least in part upon information sensed by the one or moresensors, establish a virtual barrier offset from the surface, whereinthe offset is at least one of variable or uniform, and limit movement ofthe robotic arm based at least in part upon the virtual barrier.
 20. Thesystem of claim 19, wherein the control system is further configured togenerate a three-dimensional map of the operating space based at leastin part upon information sensed by the one or more sensors.